Apparatus and method for the production of fancy yarns, such as chenille

ABSTRACT

A device for the production of fancy or fluffy yarns, such as chenille, has a frame along the length of which a plurality of individual forming units are spacedly mounted, each unit including a spindle and forming arrangement for delivering warp threads bound by encircling weft threads to a roller arrangement which also receives binder threads from a creel on the frame and which has an associated rotary knife that severs the weft threads with the warp and binder threads, having the cut weft threads thereon, being taken up on a pair of takeup spindles of a ringspinning frame. A main drive means is provided for each unit and is drivingly connected through separate transmission means with the spindle and forming arrangement, the associated roller arrangement and the associated pair of takeup spindles with each drive transmission means being adjustable for coordinated operation of such components. A separate drive means is provided for each knife which is adjustable relative to its associated roller arrangement. The twisted threads are conveyed from the spindle and forming arrangement to the roller arrangement by a feed roller assembly which is driven by the drive means for the spindle arrangement. A selectively actuatable control means for the feed roller assembly controls the feeding of the threads in the method of forming loop, seed and other fancy yarns.

United States Patent Roberts I [54] APPARATUS AND METHOD FOR THE PRODUCTION OF FANCY YARNS, SUCH AS CHENILLE [72] Inventor: Charles E. Roberts, Union, S.C.

[73] Assignee:

- Inc., New York, N.Y.

221 Filed: Aug. 25, 19199 [21 Appl.No.: 852,675

20,769 4/1882 Germany ..57/24 United Merchants and Manufacturers,

[ 1 Feb. 29, 1972 436,575 8/1933 GreatBritain ..57/24 Primary Examiner-Donald E. Watkins AttorneyMcCarthy, Depaoli, O'Brien 8L Price 571 ABSTRACT A device for the production of fancy or fluffy yarns, such as chenille, has a frame along the length of which a plurality of individual forming units are spacedly mounted, each unit including a spindle and forming arrangement for delivering warp threads bound by encircling weft threads to a roller arrangement which also receives binder threads from a creel on the frame and which has an associated rotary knife that severs the weft threads with the warp and binder threads, having the cut weft threads thereon, being taken up on a pair of takeup spindles of a ring-spinning frame. A main drive means is provided for each unit and is drivingly connected through separate transmission means with the spindle and forming arrangement, the associated roller arrangement and the associated pair of takeup spindles with each drive transmission means being adjustable for coordinated operation of such components. A separate drive means is provided for each knife which is adjustable relative to its associated roller arrangement. The twisted threads are conveyed from the spindle and forming arrangement to the roller arrangement by a feed roller assembly which is driven by the drive means for the spindle arrangement. A selectively actuatable control means for the feed roller assembly controls the feeding of the threads in the method of forming loop, seed and other fancy yarns.

20 Claims, 14 Drawing Figures Patented Feb. 29, 1972 7 Sheets-Sheet 1 zsoj zeil DRIVE 28o MOTORS O- 282 INVENTOR MASTER SWITCHES PANEL KNIFE MOTORS CHARLES E. ROBERTS BY 00m m ()Bfiw m ,0 ATT OR NEYS Patented Feb. 29, 1972 7 Sheets-Sheet 2 m/ VE/VTOR CHARLES E. ROBERTS BY WW, FIQEmm I FIG.3

AT TORNEYS Patented Feb. 29, WW2 x mwm 7 Sheets-Sheet 5 lNl/E/VTOR CHARLES E. ROBERTS ATTORNEYS Patented Feb. 29, 19?? 3fi45fl7$ 7 Sheets-Sheet 4 IIVVEIVTOR CHARLES E. ROBERTS YW MI @zprm l a (Q'EJJM ATTORNEYS Patented Feb. 29, 1972 3fi45fl78 7 Sheets-Sheet 5 FIG? I39 L 206 I38 -204 use //v I/E/VTOR CHARLES E. ROBERTS ATTORNEYS Patented Feb. 29, 1972 7 Sheets-s 6 ATTORN EYs Patented Feb. 29,1972 3,645,078

7 Sheets-Sheet 7 l/VVENTOR CHARLES E. ROBERTS BY m mm 0M E'YQEM'M ATTOR N EYS APPARATUS AND METHOD FOR THE PRODUCTION OF FANCY YARNS, SUCH AS CHENILLE BACKGROUND OF THE INVENTION 1. Field Of The Invention This invention generally appertains to improvements in yarn or thread spinning machines and, more particularly, relates to a new and novel apparatus and method for the formation and production of fancy and fluffy yarns, such as chenille, loop, seed or nub and the like.

2. Description Of The Prior Art The present invention constitutes new and novel improvements over the devices and inventions disclosed in Hortal U.S. Pat. No. 2,684,565, issued July 27, 1954 and US. Pat. No. 3,362,146, issued Jan. 9, 1968. In particular, the present invention is directed to new and novel improvements in the apparatus disclosed in the latter Hortal patent.

Hortal U.S. Pat. No. 3,362,146 discloses a chenille-forming apparatus wherein a plurality of commonly driven spindle and fonning units are mounted on a frame that supports an overhead creel holding bobbins for warp and binder threads. Each unit is composed of a stationary hollow forming member through which the warp threads are fed. A rotating spindle is disposed coaxial with the forming member and supports a cone-shaped cop comprising a single or multiple weft thread. A rotating cylindrical housing or can, having an open outer end, surrounds the cop for confining the weft thread as it is unwound, from the cop. By means of a brake and guide ring mounted in close proximity to the open end of the housing the outward travel of the unwinding weft thread is limited and controlled so that the weft thread encircles and binds the warp threads. Such weft bound warp threads are passed directly to a roller structure which draws the threads from the spindle and forming arrangement. A rotary knife is associated with the roller structure and severs the weft thread. The binder threads are fed to and drawn by the roller structure so as to combine with the warp threads and the cut weft threads. The warp and binder threads, having the severed weft threads thereon, are taken up by a pair of rotating spindles of a flyer mechanism with the severed weft threads extending outwardly from the twisted warp and binder threads and giving the formed yarn a fluffy appearance.

Not only are the spindle and the can of each unit driven from a common drive arrangement, such as a drive shaft that extends the lcngthof the frame and has a prime mover associated with one end thereof, but also, the roller structure for each unit andthe knife associated therewith are driven by such same drive shaft which, in addition, serves as the source of driving power for the takeup spindles.

In actual practice it has been found that the employment of a common drive arrangement for all of the units on the frame creates problems leading to frequent breakdowns of one or more of the units and to lack of good production quality control. The downtime of a single unit interferes with the desired productivity of the apparatus and also adds to the production costs not only in the lost operating time of a unit or units but also in the labor costs necessitated by the operator's frequent fixing attendance at the apparatus.

The use of a common drive arrangement creates vibrational forces. that appear to cause the breakdowns of the single or several units and the inability to individually control the operation of each unit requires a common control that appears too difficult to obtain in the actual running of the machine. Asa result, the yarn formed by one or more units may sometimes differ in good quality structure and appearance from other units.

Not=only does the operation of the machine with a common drive for all of the units cause problems, but, in addition, the machine does not possess any means whereby the cutter knives can be controlled and adjusted. And yet, it is the cutting relationship of each knife to its associated roller structure that determines the flufi'y appearance of the resultant yarn. The outward extension of the severed weft yarns from the twisted warp and binder yarns should be the same on the produced yarn carried by each of the takeup spindles arranged along the frame, and the structure of the twisted warp and binder yarns should be the same.

Also, it has been found that the pull on the weft and warp threads from the spindle and forming unit by the associated roller structure imposes an undue tension on such threads and should be eliminated.

In addition, it has been found that the tension placed on each thread from the bobbins on the creel is very important because the threads must be kept taut but yet the tension should not be such that breakage of the threads, during operation, occurs.

SUMMARY OF THE INVENTION In accordance with the present invention, a main drive motor is provided for each unit and drives the spindle and forming arrangement, the roller structure and the takeup spin dies for each unit through the medium of a separate drive transmission means for each of such operating components. Each drive transmission means is separately controllable and adjustable so that depending upon the desired weight, twist and length of cut weft threads of the finished yarn, the components can be adjusted to operate in a coordinated and timed relation. The same drive is used through drive transmission means for powering feed rollers which are arranged between the spindle and forming unit and the roller structure and which positively feed the warp and weft threads to the roller structure so that the threads are not drawn by the roller structure alone. Each rotary knife has its own motor which is mounted for multiple adjustments so that the position of the knife relative to the associated roller structure can be easily adjusted and controlled.

The threads from bobbins on the creel carried by the frame are fed to the forming member and to the roller structure for each unit through tensioning means which is of a most reliable but simple nature whereby the threads are kept properly taut but are not subject to breakage.

In order to make seed or loop yarn or other fancy yarns, the feed travel of the warp and weft threads from the spindle and forming arrangement to the roller structure is interrupted in a selectively controlled manner and the resultant yearn is severed by the knife or, in the instance of some loop yarn, the knife can be placed out of operation.

Accordingly, an important object of the present invention is to provide a chenille or other fancy-yarn-forming apparatus of the general nature and type, as that disclosed in the Hortal patents, particularly, US. Pat. No. 3,362,146, which will operate without experiencing any breakdowns and which will produce yarn of an excellent commercial quality with good quality control being capable of being exercised in the operation of the apparatus regardless of the number of individual units on the frame of such apparatus.

Another important object of the present invention is to provide a chenille-forming apparatus wherein the thread feeding, forming, twisting, severing and winding arrangements operate with a minimum of servicing and in a manner to produce good quality yarn.

A further important object of the present invention is to provide a novel, simple and most dependable drive means for actuating all of the working components of the chenille-forming apparatus and to provide a novelmeans for feeding and handling the threads in the formation of the yarn so that the threads are positively fed and worked without being subject to any breakage strain.

Another important object of the present invention is to provide a novel method for forming fancy yarns, such as loop and seeds yarns.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic'overall operational showing of the yam-producing apparatus of the present invention.

FIG. 2 is a diagrammatic view of the wiringarrangement for the electric motors which provide the drive for the rotary knife of each unit and for the spindle and forming arrangement, roller structure, feed roller assembly between the forming arrangement and the roller structure and the takeup spindles of the flyer mechanism.

FIG. 3 is an end elevational view of the apparatus.

FIG. 4 is a fragmentary rear elevational view of the apparatus.

FIG. 5 is a fragmentary front elevational view of the apparatus.

FIG. 6 is a fragmentary top plan view, partly in section, of the apparatus.

FIG. 7 is a detailed vertical sectional view, taken substantially on line 77 of FIG. 6, and showing the structure of the feed roller assembly and the roller structure with the rotary cutter knife.

FIG. 8 is a detailed vertical sectional view, taken substantially on line 8-8 of FIG. 7, and showing the feed roller assembly partly in front elevation and partly in section. FIG. 9 is an enlarged sectional view, taken substantially on line 9-9 of FIG. 5, and showing in side elevation one of the cans of the spindle and forming arrangement with the cop and locking means therefor being shown in dotted lines and with the assembly being shown in full line operative position and in phantom line loading position.

FIG. 10 is a transverse sectional view, taken substantially on line l0l0 ofFIG. 9.

FIG. 11 is a fragmentary sectional view, taken substantially on line 11-11 of FIG. 10, and showing the locking means for securing the spindle and forming arrangement in a working position.

FIG. 12 is a fragmentary exploded perspective view of the adjustment arrangement for the rotary knife.

FIG. 13 is a perspective showing of a selective control means for the feed roller means between the roller structure and the spindle and forming arrangement whereby the feed of the warp and weft can be patternly interrupted as one way of practicing the method of forming seed and loop or other fancy yarns.

FIG. 14 is an elevational representation of the formed seed or nub yarn.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now more particularly to the accompanying drawings, and initially to FIGS. 1 and 3 for a general understanding of the construction and operation of the yamforming apparatus 10, the apparatus 10 includes a frame, generally designated by the numeral 12, on which a plurality of separately functioning and independently operating yamforming units 15 are mounted with such units being arranged in spaced relation along the longitudinal extent of the frame. The frame 12 supports an overhead creel 14 which carries bobbins l6 and 18 containing warp threads 20 and 22 and also carries bobbins 24 and 26 which contain binder threads 28 and 30 for each unit 15. In connection with each of the units 15, the warp threads are passed through the center stationary former member 32 of a spindle and forming arrangement 35 that includes a rotating spindle 34 having mounted thereon a cone-shaped cop 36 comprising a thread or group of threads 38 constituting the weft threads which are wound around the warp threads at the outer end of the spindle and forming arrangement 35. The weft thread encircled warp threads are passed or delivered to a roller arrangement 40 by a feed roller assembly 42. Operatively associated with the roller arrangement 40 is a rotary knife 44 that cuts the weft thread, and the binder threads 28 and 30 are fed to the outer roller of the roller arrangement 40 and are there combined with the warp threads and with the cut weft threads. The resultant yarn strands are wound on rotating spindles 46 and 48 of a ring spinning frame 50, as shown in FIGS. 1 and 3, with such rotating spindles imparting a twisting action to the warp and binder threads to firmly secure the weft threads therebetween with the weft threads extending laterally outwardly therefrom in opposite directions so that the resultant yarn has a fluffy appearance. Thus, each independently operating unit 15 produces two chenille yarns of identical structure and appearance. In actual operation, all of the units 15 will be so set and operated that they will produce yarn of the same character and appearance. The number of units 15 on a frame will vary but. within practical limits, the number will be between 15 and 20.

As shown in FIGS. 1 and 5, in particular, the warp threads 20 and 22 and the binder threads 28 and 30 for each of the chenille-forming units 15 are fed to the former member 32 and to the roller arrangement 40, respectively, while being guidingly maintained under tension by a guide and tensioning means 52. Such tensioning means 52 are provided on the creel 14 and are arranged to guide the threads and maintain the threads under a constant tension so that the delivered threads are in a taut condition but maintained free from breakage. Each of the tensioning means 52 includes a pair of parallel laterally spaced-apart rods 54 and 56 that are spaced apart and disposed in such parallel relation to each other to define a cradle 58 within which a steel roller hearing or other hard cylindrical holddown body 60 is freely seated. The threads are passed over the-rods of the cradle and under the roller element 60 which thereby imposes a slight even tensioning drag thereon without any sharp tightness.

As can be appreciated from a consideration of FIGS. 4 and 5, the rods extend the full length of the creel and, as shown in FIG. I particularly, the holddown elements 60 thereon are oriented in relation to the bobbins containing the warp threads and the binder threads so that they tensioningly guide the threads downwardly relative to the working components of each unit 15, for example, the spindle and forming arrangement 35 of each unit.

The spindle and forming arrangement 35 is similar to that disclosed in Hortal US. Pat. No. 3,362,146 and, besides including the stationary former member 32 with the rotating spindle 34 coaxially disposed thereon and carrying the cop 36, comprises a cylindrical housing or can 62 that is rotatably mounted in a position to enclose the cop, as shown in FIG. 9. The cylindrical housing 62 has an open end 64 facing the roller arrangement 40 and has a closed end which supports the rotating spindle 34, the spindle and housing 62 forming an integral arrangement and having a projecting end portion 66 that is rotatably supported by a support block 68 which is fixedly anchored on the frame 12, as shown in FIGS. 9-11. The support block 68 has an upper yoke end portion 70 within which a housing or holder 72 is pivotally mounted by means of laterally projecting pins 74 rotatably joumaled in the arms of the yoke portion 70. The spindle and can projection 66 is rotatably disposed in an axial bore 68 formed in the support block 72 and the stationary former member 32 extends coaxially therewithin and through the spindle. The extending end of the projection 66 is provided with a sheave 76 that receives a drivebelt 78, as shown in FIG. 1 and as will be described.

As shown in FIG. 10, the housing 72 is seated on coil springs 80 which tend to urge the spindle and forming arrangement 35 upwardly into an inclined position, as shown in phantom lines in FIG. 9 whereby a full cop 36 may be inserted on the spindle through the open forward end 64 of the cylindrical housing or can 62. The cop 36 is locked in place on the spindle by means of a locking element 82 that is lockingly sleeved on the spindle to bearingly engage against the front of the cop.

The spindle and forming arrangement 35 is held in a down or operative position by a locking means 84, as shown in detail in FIG. 11. The locking means 84 includes a transverse opening 86 in one leg of the yoke portion 70 and a registerable surface opening 88 formed in the adjoining side of the pivoted housing 72, such openings being adapted to receive a locking bolt 90 which is manually manipulated and locked by a toggle type latching leverage 92.

nun-u: In.

As generally disclosed in I-Iortal US. Pat. No. 3,362,146, a brake and guide ring 94 is positioned in close proximity to the open end 64 of the housing 62 and, in accordance with'the present invention as shown in FIG. 9, such ring is held in a working position by means of a supporting arm 96 that is carried by clamps 100 mounted adjustably on vertical posts 102 which upstand from the top of the pivotal holder 72. The guide and brake ring is adjustable vertically of the supporting arm 46, which is also adjustable by virtue of its mounting arrangement on the supporting posts 102, as can be appreciated from a consideration of FIGS. 9 and 10.

Mounted in front of the guide and brake ring 94, as in the apparatus disclosed in the aforementioned I-Iortal patent, is the roller arrangement 40, which is composed of a series of guide, drawing and forming rollers 104, 106 and 108.'The rollers are shaped, formed and cooperatively arranged in their working relation in the same manner disclosed in such I-Iortal patenti' An electric motor 110 is provided for each of the chenille yarn forming units and is mounted on the frame 12, rearward! of its associated forming unit, as shown in FIG. 3. As can be appreciated from a consideration of FIG. 4, a motor is provided for each of the individual units 15 that are disposed in spaced relation along the longitudinal extent of the frame 12. The motor 110 has a triple sheave 112 provided on its armature shaft 114. The belt 78 is entrained on the outermost pulley of the triple sheave and drivingly engages the sheave 76 so as to rotate the spindle 34 andthe housing 62. The outermost pulley is a variable pulley of conventionalconstruction whereby its diameter can be changed to alter and controllably vary the driving speed of the belt 78 which will control the driven speed of the spindle 34 and the housing 62 so that the speed of the laying up of the weft thread on the warp threads can be controlled. A belt-tightening pulley 116 for the belt 78 is carried by a bracket 118 that is pivotally mounted by a bolt 120 on the rear of the frame so as to depend therefrom with the bracket having an arcuate adjustment slot 122 within which alocking bolt 124 is disposed in attachment to the frame.

A driving belt 126 is engaged on the innermost pulley of the triple sheave-112 and is entrained over a pulley 127 which is fixed on the outer end of a stub shaft 128 that cooperates with a right-angularly disposed stub shaft 130. The pulley 127' is a variable pulley of conventional construction whereby its diameter can be changed to alter and controllably vary the driving speed of the shaft 130. The inner ends of the stub shafts are provided with meshing bevel gears 132 housed within a gearbox 134 that is mounted on the frame and associated with each of the units, as shown in FIG. 1. The stub shaft 130 carries a pulley 136 on its outer end and the pulley 136, which may be of variable construction, is drivingly connected with a forwardly disposed pulley 138, which also may be of variable construction, by a belt 139. The pulley 138 is fixed on a shaft 140 that also carries a gear 142 which is drivingly meshed through an idler gear 144 with a gear 146. The gear 146 is fixed on a shaft 148 and provides the power for a" gear train 150 composed of three gears on the shafts of the rollers 104, 106 and 108, whereby the rollers. are driven with the roller 104 moving counterclockwise, the roller 106 moving clockwise and the outer roller 108 moving counterclockwise.

By virtue of the variable pulley 127 and, if necessary, the capability of variance of the pulleys 136 and 138, the driving speedof the driving belt 139 can be controlled and changed so as to control and change the operating speed of the roller-arrangement 40'and the associated feed roller assembly 42 depending upon the operating speed of the spindle and forming arrangement 35. Such variable pulley arrangement also serves as a belt tightener means for the driving belt 139.

The spindles 46 and 48, which constitute the takeup or flyer mechanism, are rotatably mounted on brackets 152, as shown in FIG. 3, and support bobbins 154 with a common ring rail l56being provided for all the spindles on the frame and being frame, with the suction duct having angular tubular intakevertically reciprocated and operated in a conventional manner. The whirls 158 on the spindles 46 and 48 are drivingly engaged by a driving belt 160 which is powered by a double sheave 162 connected by a crossed drive transmission belt 164 to the middle pulley of the triple sheave 112 on the motor shaft. The pulley section of the double sheave 162 on which the belt 164 is entrained is of variable construction whereby the spindle driving speed of the belt 160 can be selectively varied in accordance with the amount of twist desired in the formed yarn. Such variance of the twist between the warp and binder yarns will change the appearance and strength of the finished yarn.

The forward looped end 166 of the belt 160, after the belt drivingly engages over the whirls of the spindles, is entrained over a belt-tightening pulley 168 which is rotatably mounted on a pin 170 upstanding from a supporting block 172 that is adjustable by means of a screw rod adjustment arrangement 174, as shown in FIG. 3.

A suction duct 176, as shown in FIGS. 3 and 4, extends the length of the frame to a header 178 located at one end of the nozzles 180 that extend therefrom to a point just below the outer roller 108 of the roller arrangement 40, as shown in FIG. 7

The warp threads 20 and 22 are guided by poteyes 182 to the rods and the tensioning means 52 and to a guide pulley 184 where they are directed from a downwardly inclined posi tion from the bobbins 16 and 18 to a horizontal position for immediate entrance into the rear end of the hollow former member 32. The warp threads, upon their passage through the forward end of the former member, are encircled by the weft thread 38, as shown in FIGS. 1 and 7. The combined warp and weft threads are fed to the roller arrangement by the feed roller assembly 42, as shown in FIGS. 1, 7 and 8.

The feed roller assembly 42 comprises a shaft 186 having fluted roller bodies 188 and 190 formed in a spaced side-byside arrangement thereon. One end portion 192 of the shaft is 40 journaled by a bearing arrangement inone post 194 of a supporting yoke structure 196 for the roller arrangement 40. The

other end portion of the shaft constitutes the shaft which is rotatably mounted through the opposing post 198 and which carries the driving gear 142. The feed roller assembly further includes an overlying shaft 200, which has enlarged end portions 202 that are encompassed by rubber sleeves 204 so that the end portions constitute rubber rollers that overlie and grippingly cooperate with the hard fluted rollers 188 and 190. The shaft 200 has reduced end portions204 that are rotatably mounted in vertical slots 206 formed in the inner faces of the free upper end portions of the posts 194 and 198. The reduced central portion 208 of the shaft is engaged by a hook 210 that is formed on'the upper end of a rod 212 with the rod extending through an aperture 214 in a frame-carried support plate 216, as shown in FIG. 7, and being held by a spring 218 that engages the underside of the plate 216 and is secured by a nut 220 on the lower threaded end portion of the rod. The rod is formed at its upper end with a finger-engaging loop 222 by means of which the rod can be pulled upwardly against the coil spring218 to release the roller shaft 200 and enable the same to be removed from the supporting posts.

As shown particularly in FIG. 8, the fluted driving roller and the upper rubber roller directly in front of the extending forward tongue on theformer member-32 constitute the operating or functioning feed rollers for pulling or drawing the weft thread encircled warp threads and feeding them to the roller arrangement 40. The purpose of the adjoining pair is to provide a more operative drive and also, in the event of wear of the functioning rubber roller, the shaft 200 can be removed and turned so as to bring the previously nonthread-engaging and conveying roller into an operating position with respect to the threads. Therubber rollers are maintained under proper tensionand in driven relation with the hard fluted rollers by the spring-mounted holddown rod 212;

The binder threads 28 and 30 are guided by suitable pot or guide eyes 224 through the tensioning and guide means 52 down to the lowermost disposed guide eyes 226 where they change direction and are threaded forwardly through guide eyes 228 to be engaged by the grooved surface of the outer roller 108 of the roller arrangement 40.

The combined warp and weft threads are fed through the rollers 104 and 106 to the outer roller 108 where the warp threads engage in suitable grooves with the weft thread being set up for severing by the rotary knife 44 in the manner disclosed in I-Iortal US. Pat. No. 3,362,l46.

The rotary knife 44 is mounted on the armature shaft 230 of a suitable electric motor 232 and is provided with a fixed guard 234 that overlies the forward portion of the knife and is carried by an upstanding arm 236 mounted on the front of the frame.

It is most important from a standpoint of good quality control chenille that the rotary knife be in a carefully selected position relative to the setup weft threads so that the weft threads are severed by each unit at the same point along the transverse extent thereof between the warp threads. This is important so that the finally formed chenille yarn will have the weft threads extending laterally therefrom and consequently present the same fluffy appearance.

Thus, the individually driven rotary knife 44 for each unit is mounted so that it can be adjusted inwardly and outwardly transversely of the frame and longitudinally of the frame, all of such adjustments being of a fine nature and moving the rotary knife relative to the roller arrangement, particularly the outer forming roller 108, with which the knife cooperates. The threads are maintained in their passage through the roller arrangement under the desired tension by a tensioning means 238, which also serves as a guide for the operating inner portion of the knife, as shown in FIGS. 6 and 7 As shown in FIGS. 6 and 12, the knife operating electric motor 232 has its housing provided with a baseplate 240 provided on its underside with a longitudinal key 242 that is slidably received on a keyway 244 formed on the upper face of an underneath plate 246, The key and keyway are formed transversely of the frame and permit the motor housing to be guidingly moved laterally inwardly and outwardly of the roller arrangement, transversely of the frame. The plate 246 has an upstanding flange 248 on its outer end which is provided with a threaded opening 250 to receive an adjustment screw 252 that has its inner threaded end portion threadingly received in a threaded hole 254 formed in the baseplate 240 through the front wall thereof. By rotating the screw 252, the motor 232 can be moved inwardly and outwardly, which will result in movement of the cutter knife inwardly and outwardly relative to the outer roller 108 of the roller arrangement 40.

The frame supports a mounting plate 256 which underlies the plate 246 and which is formed on its upper surface with a transverse keyway 258 to slidably receive a transversely disposed depending key 260 formed on the underside of the plate 246. An ear 262 upstands from the side edge of the plate 256 and is provided with a threaded aperture to receive an adjustment screw 264 that has its inner end threaded into an internally threaded hole 266 formed in the side of the plate 246. By rotating the screw 264, the motor can be moved along the longitudinal axis of the frame so as to shift the knife laterally relative to the roller arrangement 40. A vertical locking bolt 268 is provided for securing the motor in set adjusted positions.

The cutter knife is positioned so as to sever the weft threads in cooperation with the roller 108 thereby providing the yarn strands which are wound on the spindles 46 and 48, such spindles imparting a twisting action to the warp and binder threads to firmly circle the weft threads therebetween and to extend laterally therefrom in opposite directions so that the yarn has an outward fluffy appearance.

As shown in FIG. 2, a main electrical circuit 270 is provided for the motors for each of the units 15 with the main line 270 coming from an electrical source through a fuse panel 272 and being divided into two powerlines 274 and 276 with the line 274 supplying electrical current for the knife motors 232 of the individual units and the line 276 supplying electrical power for the drive motors for the individual units. The powerlines 274 and 276 are each provided with master switches 278. Each of the drive motors 110 is connected in parallel with the powerline 276 and is provided with an individual switch 280 so that the drive motor for each unit can be shut off without interfering with the operation of the other drive motors 110. Similarly, the knife motors 232 are wired in parallel with the powerline 274 and are provided with individual switches 282.

Attention is now directed to FIGS. 13 and 14 wherein one means is shown in carrying out the method, in accordance with the present invention, for forming seed or nub yarn and loop or other fancy yarns.

The method of forming such fancy yarns comprises the feeding of the warp threads 20 and 22, having the weft thread 38 bindingly encircling thereon, from the outer tongue of the fonner member 32 to the roller arrangement 40 and, while so doing, imposing a drag or halt on the fed threads or, otherwise, interrupting the feeding movement of the threads in a determined but selective patterned manner so as to produce nubs or seeds 284 on the formed yarn, as shown in FIG. 14.

One manner of achieving the interruption of the feeding of the weft and warp threads or the imposing of a drag thereon is shown in FIG. 13. As illustrated therein, a timer chain 286 is provided and carries in a selected and fixed arrangement a series of timer lugs 288 which are adapted to strike the contact arm 290 of a microswitch 292. The timer chain 286 may be driven by a separate motor or, in the instance of the drive arrangement of FIG. 3, the timer chain may be driven by the shaft 162 on which the double sheave 162 is carried, Leads 294 from the microswitch are connected to a disc clutch 296 which actuates a sprocket-driven chain 298 that controls the feed roller unit 42. When the clutch is energized, it acts as a brake to impose a drag or halt on the feed rollers and this causes the weft threads to bunch up, thereby producing the nubs or seeds 284.

It is also possible to produce loops on the yarn by using the braking clutch to periodically interrupt and halt the drive. Another manner of achieving such interruption of the drive is to eliminate certain teeth on the meshing gears for the shaft 140. In the instance of the formation of the loop yarn, it is desired that the cutter knife 44 be placed out of operation and the produced yarn be taken up without the weft threads being severed. It is a simple matter to actuate the knife motor switch 282 to an off position and move the cutter knife back from the roller arrangement 40.

While it is more desirable that an individual knife motor be provided for actuating each of the rotary knives 44, it is to be understood that a drive transmission means can be drivingly coupled between the drive motor 110 for each unit and the rotary knife 44 for each unit. In any event, each of the individual forming units 15 on the frame will be operated in a manner independent of the operation of adjoining units but the units will be so set and run that from a quality control standpoint the yarn produced will be of a similar character and appearance.

In the event that the warp or binder threads for one of the individual forming units 15 should become broken or if any other accidental eventuality should occur resulting in the breakdown of a unit or its malfunctioning with regard to the production of good quality chenille yarn, it can be appreciated that, because of the individual drive arrangement for each unit 15, such affected unit can be placed out of operation, without interfering with the continuing operation of the other units. Such down or inoperative unit can then be attended to by a fixer and quickly placed back into operating condition. This is one of the decided advantages of the individual drive for each forming unit as opposed to a common drive arrangement for all of the units because with the latter arrangement, if one of the forming units breaks down or begins to malfunction, it is not possible to place it back into operating condition without shutting down all of the units, and the shutting down of all of the units is too economically expensive to be feasible. Consequently, in the common drive assembly, when the threads of one unit become broken, for example, the unit is merely left out of operation until the other units have completed an entire takeup bobbin filling cycle. However, by virtue of the individual drive arrangement of the present invention, each unit can be attended to, controlled and adjusted as an operating entity, without regard to the operating condition of the companion units on the frame.

What is claimed is:

1. An apparatus for forming fancy yarns, such as chenille, in which a plurality of individual fancy-yarn-forming units are spacedly mounted along the length of an elongated frame, each of said units comprising:

A. a warp-thread-encircling means, for encircling parallel warp threads with a weft thread,

B. a roller arrangement,

C. a takeup means,

D. an individual operating means, comprising:

i. an electric drive motor,

2. a first drive transmission means actuatingly connecting said drive motor with said warp-thread-encircling means,

3. a second drive transmission means from said drive motor for operating said roller arrangement, and

4; a third drive transmission means from saiddrive motor for actuating said takeup means, and

E. a control means for said individual operating means.

2. The apparatus of claim 1 wherein each of said individual fancy-yarn-forming units further comprises:

A. a weft-thread-carrying oop constituting the sole means for the supply of said weft thread;

B. means supplying said warp threads to said weft thread,

C. means for supplying binder threads to said roller arrangement, and l t D. a cutter means for severing said encircled weft threads, said takeup means being twisted to firmly secure said severed weft threads between said warp and binder threads.

3. The apparatus of claim 2 wherein each of said fancyyam-forming units further comprises, as said warp-thread-encircling means:

.A. a hollow stationary former member, having an outer tongue end, through which said warp threads are fed,

-B. a rotary spindle coaxially disposed on said former member and carrying said weft-thread-carrying cop, and

C. a rotary cylindrical housing which:

. 1. extends over said cop and confines unwinding weft threads therewithin,

2. has an open end at said outer tongue end, and

3. has means-at said open end for directing said weft thread into encircling engagement of said warp threads issuing at said tongue end of said former member.

4. The apparatus of claim 3 wherein in each of said fancyyam-forming units: I

A. said roller arrangement is operatively mounted on said frame, is disposed forwardly of said tongue end, and is adapted to receive said binder threads along-with said warp and encircling weft threads,

B. said cutter means is a rotary knife mounted on said frame and operatively associated with said roller arrangement for severing said weft threads, and

C. said takeup means is a pair of spindles carried by said frame.

5. The apparatus of claim 2 wherein each of said drive transmission means is individually adjustable to selectively vary the operating speed thereof.

6. The apparatus of claim 2 including a separate electrical motoradjustably mounted on the frame for rotatively operating said cutter means for each fancy-yarn-forming unit.

7. The apparatus of claim 5 wherein said control means is operatively carried by each of the transmission means for adjustably controlling the operating speed thereof.

8. The apparatus of claim 4 and including a separate electric motor mounted on said frame for rotatively operating said rotary knife.

9. The apparatus of claim 8 wherein said knife motor is mounted in said frame for adjustment laterally and longitudinally of the frame relative to said roller structure.

10. The apparatus of claim 4 wherein:

A. said takeup spindles include whirls,

B. said drive motor has an armature shaft provided with a triple sheave, and

C. said third drive transmission means includes:

1. an idler double sheave having a variable pulley section constituting said adjustable control means for said third drive transmission means,

2. a belt connecting said sheaves,

3. a belt drivingly encircling said whirls and mounted on the idler double sheave, and

4. adjustment means for said belt.

11. The apparatus of claim 10 wherein said adjustment means includes an idler pulley engaging a loop end of said belt intermediate said takeup spindles and means mounting said idler pulley on the frame for belt adjustment movement toward and away from said takeup spindles.

12. The apparatus of claim 10 wherein said first drive transmission means includes:

A. a driven sheave carried by said rotary spindle and the surrounding housing,

B. a belt connecting said triple sheave and said driven sheave, said triple sheave having a variable pulley section on which the belt is engaged and which constitutes the adjustable control means for the first drive transmission means, and

C. a belt tightener means for said belt including:

1. an idler pulley,

2. a bracket supporting said pulley, and

3. means mounting said bracket on the frame for belt tightening adjustments.

13. The apparatus of claim 12 wherein said second drive transmission means includes a gearing, an input and an output shaft connected by said gearing, a variable pulley on said input shaft, a belt connecting said variable pulley to said triple sheave, said variable pulley constituting the adjustable control means for the second drive transmission means, and a drive transmission belt connecting said output shaft to said roller arrangement.

14 The apparatus of claim 13 wherein a feed roller means is operatively interposed between said roller arrangement and said tongue end of said former member for positively feeding the warp and weft threads to the roller arrangement, said feed roller means being driven by the drive transmission belt for the roller arrangement.

15. The apparatus of claim 14 wherein said feed roller means includes:

A. a hard fluted roller which is positively driven and disposed transversely of the issuing weft and warp threads and underlying the same,

B. a rubber roller overlying said fluted roller in parallel frictional engagement therewith, said rubber and fluted rollers providing a gripping and feeding nip for the threads, and

C. a spring holddown means for said rubber roller for holding the same in firm engagement with the fluted roller.

16. The apparatus of claim 1 including an overhead creel supported by said frame and supporting bobbins containing warp and binder threads for each of said units and tensioning means for guiding said threads to the frame, said tensioning means including a pair of parallel, spaced-apart rods defining an open cradle and a hard cylindrical body freely mounted in said cradle and engaging said rods with the warp and binder threads traveling in the cradle under said body.

18. The unit of claim 17 wherein one of said rollers has a driven shaft and the other has an idler shaft, means for driving said driven shaft in timed relation with the forming means and the roller arrangement.

19. The unit of claim 18 and including means for periodically pattemly interrupting said shaft driving means.

20. The unit of claim 18 and including spring tensioning means coupling said rollers.

nuns: Am: 

1. An apparatus for forming fancy yarns, such as chenille, in which a plurality of individual fancy-yarn-forming units are spacedly mounted along the length of an elongated frame, each of said units comprising: A. a warp-thread-encircling means, for encircling parallel warp threads with a weft thread, B. a roller arrangement, C. a takeup means, D. an individual operating means, comprising:
 1. an electric drive motor,
 2. a first drive transmission means actuatingly connecting said drive motor with said warp-thread-encircling means,
 3. a second drive transmission means from said drive motor for operating said roller arrangement, and
 4. a third drive transmission means from said drive motor for actuating said takeup means, and E. a control means for said individual operating means.
 2. a first drive transmission means actuatingly connecting said drive motor with said warp-thread-encircling means,
 2. a belt connecting said sheaves,
 2. has an open end at said outer tongue end, and
 2. a bracket supporting said pulley, and
 2. The apparatus of claim 1 wherein each of said individual fancy-yarn-forming units further comprises: A. a weft-thread-carrying cop constituting the sole means for the supply of said weft thread; B. means supplying said warp threads to said weft thread, C. means for supplying binder threads to said roller arrangement, and D. a cutter means for severing said encircled weft threads, said takeup means being twisted to firmly secure said severed weft threads between said warp and binder threads.
 3. The apparatus of claim 2 wherein each of said fancy-yarn-forming units further comprises, as said warp-thread-encircling means: A. a hollow stationary former member, having an outer tongue end, through which said warp threads are fed, B. a rotary spindle coaxially disposed on said former member and carrying said weft-thread-carrying cop, and C. a rotary cylindrical housing which:
 3. means mounting said bracket on the frame for belt tightening adjustments.
 3. has means at said open end for directing said weft thread into encircling engagement of said warp threads issuing at said tongue end of said former member.
 3. a belt drivingly encircling said whirls and mounted on the idler double sheave, and
 3. a second drive transmission means from said drive motor for operating said roller arrangement, and
 4. a third drive transmission means from said drive motor for actuating said takeup means, and E. a control means for said individual operating means.
 4. adjustment means for said belt.
 4. The apparatus of claim 3 wherein in each of said fancy-yarn-forming units: A. said roller arrangement is operatively mounted on said frame, is disposed forwardly of said tongue end, and is adapted to receive said binder threads along with said warp and encircling weft threads, B. said cutter means is a rotary knife mounted on said frame and operatively associated with said roller arrangement for severing said weft threads, and C. said takeup means is a pair of spindles carried by said frame.
 5. The apparatus of claim 2 wherein each of said drive transmission means is individually adjustable to selectively vary the operating speed thereof.
 6. The apparatus of claim 2 including a separate electrical motor adjustably mounted on the frame for rotatively operating said cutter means for each fancy-yarn-forming unit.
 7. The apparatus of claim 5 wherein said control means is operatively carried by each of the transmission means for adjustably controlling the operating speed thereof.
 8. The apparatus of claim 4 and including a separate electric motor mounted on said frame for rotatively operating said rotary knife.
 9. The apparatus of claim 8 wherein said knife motor is mounted in said frame for adjustment laterally and longitudinally of the frame relative to said roller structure.
 10. The apparatus of claim 4 wherein: A. said takeup spindles include whirls, B. said drive motor has an armature shaft provided with a triple sheave, and C. said third drive transmission means includes:
 11. The apparatus of claim 10 wherein said adjustment means includes an idler pulley engaging a loop end of said belt intermediate said takeup spindles and means mounting said idler pulley on the frame for belt adjustment movement toward and away from said taKeup spindles.
 12. The apparatus of claim 10 wherein said first drive transmission means includes: A. a driven sheave carried by said rotary spindle and the surrounding housing, B. a belt connecting said triple sheave and said driven sheave, said triple sheave having a variable pulley section on which the belt is engaged and which constitutes the adjustable control means for the first drive transmission means, and C. a belt tightener means for said belt including:
 13. The apparatus of claim 12 wherein said second drive transmission means includes a gearing, an input and an output shaft connected by said gearing, a variable pulley on said input shaft, a belt connecting said variable pulley to said triple sheave, said variable pulley constituting the adjustable control means for the second drive transmission means, and a drive transmission belt connecting said output shaft to said roller arrangement.
 14. The apparatus of claim 13 wherein a feed roller means is operatively interposed between said roller arrangement and said tongue end of said former member for positively feeding the warp and weft threads to the roller arrangement, said feed roller means being driven by the drive transmission belt for the roller arrangement.
 15. The apparatus of claim 14 wherein said feed roller means includes: A. a hard fluted roller which is positively driven and disposed transversely of the issuing weft and warp threads and underlying the same, B. a rubber roller overlying said fluted roller in parallel frictional engagement therewith, said rubber and fluted rollers providing a gripping and feeding nip for the threads, and C. a spring holddown means for said rubber roller for holding the same in firm engagement with the fluted roller.
 16. The apparatus of claim 1 including an overhead creel supported by said frame and supporting bobbins containing warp and binder threads for each of said units and tensioning means for guiding said threads to the frame, said tensioning means including a pair of parallel, spaced-apart rods defining an open cradle and a hard cylindrical body freely mounted in said cradle and engaging said rods with the warp and binder threads traveling in the cradle under said body.
 17. In an individual chenille-forming unit which includes forming means for winding weft threads on warp threads and a roller arrangement to which such threads are passed, the improvement comprising positive feed means operatively interposed between said forming means and the roller arrangement for feeding the threads to the roller arrangement, said feed means including a pair of upper and lower engaging feed rollers arranged transversely of the forming means and grippingly engaging the threads.
 18. The unit of claim 17 wherein one of said rollers has a driven shaft and the other has an idler shaft, means for driving said driven shaft in timed relation with the forming means and the roller arrangement.
 19. The unit of claim 18 and including means for periodically patternly interrupting said shaft driving means.
 20. The unit of claim 18 and including spring tensioning means coupling said rollers. 